Friction damped insert for highly stressed engineering components

ABSTRACT

A friction damped insert for highly stressed engineering components is disclosed. The disclosed inventive concept provides a method and system for increasing the damping capacity of an engineering system by adding a non-flat solid, highly damped insert to a system component that contributes most to the system&#39;s dynamic response. The insert can either be embedded into a system component during casting or be fastened to the system component outer surface. The insert is made of the single layer of flexible material by forming it into a rigid elongated body. The layer of material can be turned over on itself without folding to create a cylinder or can be folded over a number of times to create a prismatic bar. The layer of material may be shaped into a corrugated panel. The layer of flexible material may have a number of relatively small openings or perforations with a uniform spatial distribution.

RELATED APPLICATION

The present application is a divisional application of U.S.Non-provisional application Ser. No. 16/209,432, filed Dec. 4, 2018 towhich prior is claimed under 35 U.S.C. § 120 and of which the entirespecification is hereby expressly incorporated by reference.

TECHNICAL FIELD

The disclosed inventive concept relates to dampening systems and methodsof manufacturing such systems. More particularly, the disclosedinventive concept relates to such a system in which a non-flat solid,highly damped insert is embedded in a component during the moldingprocess or is attached to a component. The system component in which theinsert is embedded or is attached is a component that contributessignificantly to the dynamic response of the system. The damped insertis made of a single layer of flexible material formed into a rigidelongated body having inner and outer surfaces. If the damped insert isembedded in the component during the molding process, the layer ofmaterial may have a number of relatively small openings or perforationsto allow a limited infiltration of the molten casting material insidethe layer of material for the additional spot rigid bonding between thecomponent and insert inner surfaces during the casting process.

BACKGROUND OF THE INVENTION

A significant number of excessive noise and vibration problems inmechanical and civil engineering are caused by a mechanical systemresonance which can occur whenever the natural frequency of vibration ofa system coincides with the frequency of the external excitation.Mechanical system resonance may lead to excessive dynamic deflectionswhich could cause not only undesirable noise and vibration but even asystem failure. It is also known that coulomb friction develops fromrelative movement at the interface between the opposing solid surfaces.

Previous approaches to managing the relationship between frictionallydamped structural components used embedded solid inserts that had onlyouter surfaces. Correspondingly, to develop sliding interface betweenthe insert and the structural component, previous approaches proposedpre-treating the insert surfaces to avoid their complete bonding withthe component surfaces during casting. However, while providing certainadvantages, this can lead to insufficient overall bonding between theinsert and component surfaces which may impact component structuralintegrity, representing a safety concern.

It is also known for engineers today to use Computer Aided Engineering(CAE) and Experimental Modal Analysis (EMA) tools to modify stiffness ormass of the system components to prevent the occurrence of a resonance.However, these procedures are expensive, time-consuming, and not 100%robust to the normal variations in parts associated with high-volumemanufacturing. At the same time, the resonant vibration amplitudestrongly depends on the overall damping of the system. With highersystem damping, the resonant response of the system is lower. Materialsthat are commonly used for engineering structures have relatively lowdamping capacity. Correspondingly, the overall system damping typicallyis also low. Therefore, it would be highly beneficial to increase theinternal damping capacity of the structural components that contributemost to the system dynamic deflections. This would robustly attenuatethe system resonant vibration upon its development before it couldproduce noise in the system. Thus, a long-term concern for bothcustomers and OEMs would be significantly reduced.

As in so many areas of engineering technology there is always room formeasures that increase the damping capacity of engineering systems. Anew approach that provides optimum damping capacity in an engineeringsystem is desired.

SUMMARY OF THE INVENTION

The disclosed inventive concept provides a method and system forincreasing the damping capacity of an engineering system by adding anon-flat solid, highly damped insert to a system component thatcontributes most to the dynamic response of the system. The solid insertcan either be embedded into a system component during the castingprocess or be fastened to the system component outer surface by welding,gluing or by other means. The insert is made of the single layer offlexible material (e.g., metal or plastic) by forming it into a rigidelongated body having both inner and outer surfaces. For example, thelayer of material can be turned over and over on itself without foldingto create a cylinder or it can be folded over a number of times tocreate a prismatic bar.

In yet another example of the disclosed inventive concept, the layer ofmaterial can be shaped into a corrugated panel with some or all of thepanel corrugations having opposing inner surfaces to be pressedtogether. Thus, if the insert body is subjected to dynamic loading, itsvibrational energy may be dissipated by frictional contact at thecorresponding inner surfaces. The spatial and cross-sectionalconfigurations of the insert within the component can be adjusted totailor its damping capacity to the component region that has the highestvibration amplitude during the system resonance.

To preserve the structural integrity of a component containing embeddedinsert, the outer surfaces of the insert are completely bonded to thecomponent casting material during the molding process. According toanother feature of this invention, the layer of flexible material mayhave a number of relatively small openings or perforations with auniform spatial distribution. Their purpose is to allow a limited andlocal (i.e., just inside and in the immediate vicinity of the openings)infiltration of the molten casting material inside the layer of materialfor the additional spot rigid bonding between the component and insertinner surfaces during the casting process. The limited spot rigidbonding between the insert and component surfaces helps avoid thereduction in the contact pressure at the frictional interface betweenthe inner surfaces of the insert due to their unavoidable thermaldistortion during the component casting process. This arrangement alsohelps prevent undesirable differences in the temperature fields withinthe component and the insert during the system service life. Suchdifferences might result in thermal distortion of the insert within thecomponent which would negatively impact contact pressure between theinsert inner surfaces.

It is known that friction damping has a preferred range of contact force(contact pressure) within which it becomes most effective. Below such anoptimum range, excess relative motion at the interface develops withoutsignificant energy dissipation. Above it, excess contact pressure limitsthe development of relative motion for friction to act as an effectivedamper. Contact pressure between two opposing surfaces depends on theircontact geometry and elastic properties which are influenced by theinterface temperature and the corresponding temperature gradients. Theoperating temperature range for engineering systems is very wide (from−40° C. in cold climate areas during winter time up to 500° C. near thesources of heat). Since unwanted noise and vibration levels might occurduring any temperature conditions, the change in the insert dampingeffectiveness with the component temperature should be minimized. Thepresent invention achieves that by minimizing the variation between thetemperature fields and their gradients inside the component and theinsert as described above.

The above advantages and other advantages and features will be readilyapparent from the following detailed description of the preferredembodiments when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this invention, reference shouldnow be made to the embodiments illustrated in greater detail in theaccompanying drawings and described below by way of examples of theinvention wherein:

FIG. 1 is a perspective view of a single layer of flexible materialhaving perforations prior to folding;

FIG. 2 is a cross section of a corrugated panel-like insert formed fromthe perforated layer of flexible material;

FIG. 3 is a cross section of another corrugated panel-like insert formedfrom the perforated layer of flexible material;

FIG. 4 is a cylindrical insert formed by a rolled layer of perforatedflexible material;

FIG. 5 is a rigid, elongated damped insert formed by folded layers ofperforated flexible material;

FIG. 6 is a perspective view of a beam-shaped component having a rolleddamped insert embedded therein, the rolled damped insert beingillustrated by dashed lines;

FIG. 7 is a sectional view of a portion of a cast component illustratinga perforation of the embedded damped insert in which molten componentmaterial entered the perforation and is bonded to the outer surface ofthe damped insert; and

FIG. 8 is a perspective view of a beam-shaped component having a rolleddamped insert attached to an inner surface thereof, the rolled dampedinsert being illustrated by dashed lines.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following figures, the same reference numerals will be used torefer to the same components. In the following description, variousoperating parameters and components are described for differentconstructed embodiments. These specific parameters and components areincluded as examples and are not meant to be limiting.

The accompanying figures and the associated description illustrate theconstruction of and method of making a non-flat solid, highly dampedinsert. The damped insert is preferably embedded in a component duringthe molding process. Alternatively, the damped insert may be attached toa component by any one of several methods of attachment. The dampedinsert of the disclosed inventive concept is attached to a componentwhich plays an important role in the dynamic response of the system.

The accompanying figures are not intended as being limiting but insteadare intended as being illustrative of the disclosed inventive concept.FIGS. 1 through 3 illustrate a damped insert in the form of a sheethaving a plurality of perforations formed therein. FIGS. 4 and 5illustrate the damped insert in the form of a perforated sheet in coiledand folded configurations respectively for use with a system component.As shown in FIGS. 4 and 5 , a sheet of flexibly foldable or coilablematerial is used to make the depicted damped inserts. FIGS. 6 and 8illustrate the formed damped insert in position cast within and attachedto a system component respectively. A sectional view of a portion of acast component in which molten component material entered theperforation and bonded to the outer surface of the damped insert isillustrated in FIG. 7 .

The formed damped insert of the disclosed inventive concept may be usedin any system component which would benefit by a damping element. Such acomponent may be used in virtually any industry in which vibration is anundesirable characteristic. Such industries include, without limitation,the transportation industry and the construction industry. Accordingly,reference to “system component” when used herein is to be given itsbroadest interpretation.

Referring to FIG. 1 , a single layer of a flexible material isillustrated as 10. The single layer of a flexible material 10 may becomposed of a variety of materials, including any one of several metalsor plastics. The single layer of flexible material 10 includes aplurality of perforations 12 formed therein. The perforations 12 arepreferably formed through the single layer of flexible material 10 toallow for the inflow of molten material as discussed below with respectto FIG. 7 . The number, placement and size of the small openings orperforations 12 may be varied. The sizes of the small openings orperforations 12 may be consistent throughout the single layer offlexible material 10 or may be different. The number, placement and sizeof the small openings or perforations 12 may be readily adapted for anyparticular need and are thus an important feature of the tunability ofthe disclosed inventive concept. More particularly, and as anon-limiting example, the number of small openings or perforations 12can be adjusted to allow for improved thermal expansion compatibilitybetween the materials of the insert and the component that uses it.

A cross section of an exemplary corrugated panel-like insert, generallyillustrated as 20, is shown in FIG. 2 . The corrugated panel-like insert20 includes a plurality of corrugations 22, 22′ and 22″. A greater orlesser number of corrugations may be adopted. In addition, while thecorrugations 22, 22′ and 22″ are shown in FIG. 2 as being evenly spaced,such even spacing is not necessary.

Formed within the folded area of each of the corrugations 22, 22′ and22″ is a frictional interface. Specifically, a frictional interface 24is formed within the corrugation 22, a frictional interface 24′ isformed within the corrugation 24′, and a frictional interface 24″ isformed within the corrugation 24″.

While the corrugated panel-like insert may include corrugations formedon one side of the panel as is the case with the corrugated panel-likeinsert 20 illustrated in FIG. 2 and discussed in relation thereto, thecorrugations may be provided on both sides of the panel. An example ofsuch a construction is illustrated in FIG. 3 in which a cross section ofan exemplary corrugated panel-like insert, generally illustrated as 30,is shown. The corrugated panel-like insert 30 includes a plurality ofcorrugations 32, 32′, 32″ and 32′. Like the corrugated panel-like insert20 illustrated in FIG. 2 , a greater or lesser number of corrugationsmay be adopted for use in the corrugated panel-like insert 30.Similarly, while the corrugations 32, 32′, 32″ and 32″ are shown in FIG.3 as being evenly spaced, such even spacing is not necessary.

Formed within the folded area of each of the corrugations 32, 32′, 32″and 32″ is a frictional interface. Specifically, a frictional interface34 is formed within the corrugation 32, a frictional interface 34′ isformed within the corrugation 34′, a frictional interface 34″ is formedwithin the corrugation 34″, and a frictional interface 34′″ is formedwithin the corrugation 34″.

FIGS. 1 through 3 illustrate sheets formed from a flexible material foruse in a rigid, elongated body having both inner and outer surfaces foruse as a system component. FIGS. 4 and 5 illustrate the damped insertitself in different applications. Each sheet may be turned over and overonto itself by rolling or coiling without folding resulting in thedamped insert or may be folded over a number of times to create, forexample, a damped prismatic bar. It is to be understood that theillustrated applications are intended to be suggestive and not limiting.

With reference to FIG. 4 , a coiled cylindrical insert, generallyillustrated as 40, is shown. The coiled cylindrical insert 40 is formedfrom a coiled flexible material 42 that may be of virtually anythickness. A plurality of perforations 44 is formed in the coiledflexible material 42. A greater or lesser number of perforations 44 maybe provided. In addition, the location and spacing of the perforations44 may be different from the locations and spacing illustrated and maybe of any configuration.

With reference to FIG. 5 , a rigid and elongated damped insert formed byfolded layers of perforated flexible material, generally illustrated as50, is shown. The rigid and elongated damped insert 50 is formed fromone or more segments of a layered and folded material 52 that may be ofvirtually any thickness. A plurality of perforations 54 is formed in thelayered and folded material 52. A greater or lesser number ofperforations 54 may be provided. In addition, the location and spacingof the perforations 54 may be different from the locations and spacingillustrated and may be of any configuration.

As noted, the damped inserts illustrated in FIGS. 4 and 5 are suggestiveand not intended as limiting as other configurations may be adapted foruse in the disclosed system. Regardless of its configuration, the dampedinsert, once formed, may either be embedded in a cast component or maybe attached to a component. Both approaches to assembly help to achievethe goal of providing damping.

With reference to FIG. 6 , a solid article, such as a beam-shapedcomponent, is generally illustrated as 60. The beam-shaped component 60includes an embedded cylindrical friction damped insert 62 embeddedwithin a solid beam body 64. More than one embedded cylindrical frictiondamped insert 62 may be embedded within the solid beam body 64. Theshape and size of the embedded cylindrical friction damped insert 62 asillustrated is only suggestive and is not intended as being limiting.

The embedded damped insert is embedded in the component during themolding process, the layer of material may have a number of relativelysmall openings or perforations 66 to allow a limited infiltration of themolten casting material inside the layer of material for the additionalspot rigid bonding between the component and insert inner surfacesduring the casting process. This arrangement is illustrated in FIG. 7 .

Referring to FIG. 7 , section of a cast component, generally illustratedas 80, is shown. The cast component 80 includes an embedded insert 82.The embedded insert may be of either the coiled cylindrical insert 40 orthe rigid and elongated damped insert 50 illustrated in FIGS. 4 and 5respectively and discussed in relation thereto. The embedded insert 82includes multiple layers. As illustrated, the embedded insert 82includes insert layers 84, 86, 88, and 90 of which the layer 84 is theoutermost layer. The upper surfaces of the layers 82 and 84 define abonding layer or outer insert surface 92. Small openings orperforations, of which one small opening or perforation 94 isillustrated, are formed in the outermost layer 84. The small openings orperforations 94 allow for the inflow of a molten material, such as acomponent bulk material 96, as discussed below.

As noted above with respect to FIG. 1 , the number of small openings orperforations 94 can be adjusted to allow for improved thermal expansioncompatibility between the materials of the insert and the component thatuses it. Particularly, the number of openings may range from 0.1% up to50% of the surface area of the outermost layer 94 of the embedded insert82. This allows for adjustment of the thermal expansion propertiesbetween the materials of the bonding layer or outer insert surface 92and the insert material removing the requirement for them to havesimilar coefficients of the thermal expansion. If the bonded materialshave different coefficients of the thermal expansion they can developcracks within their bonding layer and the insert material which cancomprise the structural integrity of the component.

To prepare the cast component, the insert 82 is placed in the mold (notshown) and is held in position by an appropriate arrangement such astabs. The molten component bulk material 96 is poured into the mold.Upon pouring of the molten material into the mold, a bonding layer 98 isformed that is bonded to the perforation and the associated outer insertsurface 92 comprising the layers 82 and 84, thereby providing a strongattachment between the insert 82 and the surrounding component bulkmaterial 96.

Optionally, the damped insert of the disclosed inventive concept may beattached to a component requiring damping as opposed to being cast inthe component as illustrated in FIGS. 6 and 7 and as discussed inrelation thereto. A component having a damped component attached theretois illustrated I FIG. 8 .

Referring to FIG. 8 , a perspective view of a thin-walled beam-shapedcomponent having attached cylindrical friction damped insert isgenerally illustrated as 100. The thin-walled beam-shaped component 100comprises a thin-walled beam 102 having an interior 104 formed therein.A damped insert, such as a cylindrical damped insert 106, is attached tothe interior 104 of the thin-walled beam 102. Attachment may be made atone or more attachment points 108 by any of several methods including,without limitation, welding or other mechanical fastening. It is to beunderstood that while it is illustrated that the attached insert is thecylindrical damped insert 106, any other damped insert according to thedisclosed inventive concept may be adapted for use with the component.It is also to be understood that it is not necessary for the dampedinsert 106 to be attached to the interior 104 of the thin-walled beam102. Instead, the damped insert 106 may be fixed to the outside of thecomponent.

The damped insert of the disclosed inventive concept may be used in anenvironment where damping is necessary and finds particular applicationin a highly stressed engineering component. For example, as anon-limiting example, the disclosed inventive concept may be used in theautomotive industry to dampen brake drums and brake rotors.

One skilled in the art will readily recognize from such discussion, andfrom the accompanying drawings and claims that various changes,modifications and variations can be made therein without departing fromthe true spirit and fair scope of the invention as defined by thefollowing claims.

What is claimed is:
 1. A method for forming a damped component, themethod comprising: forming a friction damped insert associated with acomponent body, said friction damped insert being formed from a sheet offlexibly foldable or coilable material, said sheet of flexibly foldableor coilable material having first and second sides and being folded toform a prismatic bar or coiled into a configuration of a non-flatelongated body or formed into a corrugated shape, said sheet of flexiblyfoldable or coilable material having a plurality of perforations formedtherein that are configured to allow molten material to flow therein;forming a component to be damped; and attaching said friction dampedinsert to said component to be damped.
 2. The method for forming thedamped component of claim 1, including forming a component mold,positioning said friction damped insert in said mold, and introducing amolten component bulk material into said mold to surround said frictiondamped insert and to infuse a portion of said molten component bulkmaterial into said plurality of perforations.
 3. The method for formingthe damped component of claim 1, wherein said sheet of flexible foldableor coilable material is selected from the group consisting of a metaland a plastic.
 4. The method for forming the damped component of claim1, wherein said plurality of perforations extend between said first sideand said second side of said sheet of flexible foldable or coilablematerial.
 5. The method for forming the damped component of claim 1,wherein said sheet of flexible foldable or coilable material is foldedover itself in the shape of a prismatic bar.
 6. The method for formingthe damped component of claim 1, wherein said sheet of flexible foldableor coilable material is formed into a corrugated having that includes atleast one corrugation, said at least one corrugation having a frictionalinterface.
 7. The method for forming the damped component of claim 6,wherein said at least one corrugation comprises a plurality ofcorrugations, each of said plurality of corrugations being formed on oneside of said first side or said second side.
 8. The method for formingthe damped component of claim 6, wherein said at least one corrugationcomprises a plurality of corrugations, each of said plurality ofcorrugations being formed on both said first side and said second side.